Method of forming foundry molds



y 30, 1961 E. L. FRANKENSTEIN 2,985,931

METHOD OF FORMING FOUNDRY MOLDS Filed Oct. 16, 1958 Fig.|.

5 Sheets-Sheet l INVENTOR Edgar L. Frankenstein 5 Sheets-Sheet 2 May 30, 1961 E. FRANKENSTEIN METHOD OF FORMING FOUNDRY MOLDS Filed Oct. 16, 1958 Fig.3.

May 30, 1961 Filed Oct. 16, 1958 E. L. FRANKENSTEIN METHOD OF FORMING FOUNDRY MOLDS 5 Sheets-Sheet 3 INVENTOR Edqor L. Frankenstein dew/7 May 30, 1961 E. 1.. FRANKENSTEIN METHOD OF FORMING FOUNDRY MOLDS 5 Sheets-Sheet 4 Filed Oct. 16, 19.58

INVENTOR Edgar L. Frankenstein 521 7 May 30, 1961 E. FRANKENSTEIN METHOD OF FORMING FOUNDRY MOLDS 5 Sheets-Sheet 5 Filed Oct. 16, 1958 lNVENTOR Edgar L. Frankenstein United States Patent METHOD OF FORMING FOUNDRY MOLDS Edgar L. Frankenstein, Zelienople, Pa., assignor to Herman Pneumatic Machine Company, Pittsburgh, Pa., a corporation of Pennsylvania Filed Oct. '16, 1958, Ser. No. 767,599

8 Claims. (Cl. 22197) This invention relates to a method of forming foundry molds. It has to do with a method for mass producing foundry molds of high quality with unprecedented efliciency.

My method may be practiced by the use of apparatus of various difierent types and indeed may to a considerable extent be practiced by hand, although it may be practiced most efliciently by the use of appropriate apparatus. One form of apparatus which may be used for practice of my method is disclosed in my copending application Serial No. 767,600, filed on even date herewith.

By use of my method patterns and flasks are speedily and accurately assembled, finely divided mold forming material is delivered thereto, the mold forming material is compacted and the flasks with the compacted molds therein are stripped from the patterns which repeat the cycle with other flasks so that a continuous flow of foundry molds is produced which are delivered one after another and may be conveyed to the casting station.

In a production run two patterns are employed which alternately form molds. The patterns may be. identical or not as desired. For example, one may be a cope pattern and the other may be a drag pattern for forming cope and drag mold sections respectively which may be assembled to form completed molds. The molds formed by one pattern are delivered at one station and the molds formed by the other pattern are delivered at another station and provision may be made for trans,- ferring the molds to an assembly station if they are to constitute the cope and drag halves of an assembled mold.

In a preferred procedure my method of forming foundry molds comprises shifting patterns each with a flask thereon alternately from opposite sides of a compacting station, introducing finely divided mold forming material into each flask and against the pattern carrying the flask, at the compacting station compacting the finely divided mold forming material in each flask against the pattern carrying the flask, shifting each pattern and flask with a compacted mold thereon and therein away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station and stripping each flask and mold from the pattern against which the mold was formed. The finely divided mold forming material is preferably introduced into each flask and against the pattern carrying the flask during the shifting of each such pattern and flask to the compacting station. Desirably the mold forming material is also stricken off during the shifting of the pattern and flask to the compacting station.

The shifting of each pattern and flask with a compacted mold thereon and therein away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station is preferably eifected simultaneously with the shifting of a pattern with a flask thereon to the compacting station from the opposite side of the compacting station.

I further provide a method of forming foundry molds comprising shifting a pattern with a flask thereon generally horizontally to a compacting station, introducing finely divided mold forming material into the flask and against the pattern, at the compacting station lowering the pattern, flask and mold forming material into operative position, compacting the mold forming material in the flask against the pattern, thereafter raising the pattern, flask and mold and then shifting the pattern, flask and mold generally horizontally away from the compacting station and stripping the flask and mold from the pattern. 1

I preferably raise the flask and mold to strip the flask and mold from the pattern. I preferably convey away the flask and mold generally horizontally at the elevation to which they are raised to strip them from the pattern.

Upon conveying away the flask and mold I preferably move another flask into position above the pattern and lower such other flask into cooperative relationship with the pattern for reception of finely divided mold forming material to form another mold. The movement of such other flask into position above the pattern is preferably accomplished simultaneously with the conveying away of the flask and previously formed mold. I preferably clean and spray the pattern between the raising of the flask and mold to strip the flask and mold from the pattern and the lowering of the succeeding flask into cooperative relationship with the pattern.

I preferably convey away each flask and compacted mold in a direction transverse of the direction of move ment of the pattern, flask and mold away from the compacting station and move another flask into cooperative relationship with the pattern for reception of finely divided mold forming material to form another mold. I preferably move such other flask into cooperative relationship with the pattern simultaneously with the con-' veying away of the flask .with the previously formed mold, and I preferably move such other flask in the same transverse direction as that in which the flask with the previously formed mold is conveyed away.

The preferred methodof compacting the mold forming material is more specifically described and claimed in copending application Serial No. 741,826, filed June 13, 1958, now abandoned, and copending application Serial No. 745,381, filed June 30, 1958. The first mentioned copending application is directed to the self-adjusting squeeze head which I prefer to employ and the second mentioned copending application is directed ,to the carrying of the squeezing means by the jolt table. I prefer to utilize a self-adjusting squeeze head carried by the jolt table although the mold forming material may be otherwise compacted. The compacting maybe accomplished by jolting alone or by squeezing alone but most eflicient results are obtained by a combination of jolting and squeezing, particularly when a self-adjusting squeeze head is employed and is carried by the jolt table.

Other details, objects and advantages of the invention will become apparent as the following description of a present preferred method of practicing the same proceeds.

In the accompanying drawings I have shown one form of apparatus which may be employed in practicing my: invention and have illustrated the practice of the invention in which:

Figured is a top plan view of foundry mold formingv apparatus with the squeeze head and a portion of the mechanism at one end of the apparatus cut away;

Figure 2 is an elevation of the apparatus shown in Figure 1 as viewed from the left in Figure 1;

Figure 3 is a vertical cross-sectional view taken along the line III-III of Figure 1;

Figure 4 is an end elevational view of the apparatus;

and

Figure is a vertical cross-sectional view taken along the line V-V of Figure 4.

The apparatus shown in the drawings is one form of apparatus which may be employed in practicing the invention and for purposes of explanation and illustration the invention will be described as practiced by the use of such apparatus although it is to be distinctly understood that other forms of apparatus may be employed and indeed to a considerable extent the invention may be practiced by hand.

Referring now more particlularly to the drawings, my entire apparatus may be mounted on a single foundation or three separate foundations may be provided, one for the central portion of the apparatus which comprises the compacting station and one for each of the end portions of the apparatus which comprise the stripping stations. At the center of the apparatus viewing Figure 3 is a jolt table 2 adapted to be jolted by any suitable jolting means as well known to those skilled in the art, the jolt table carrying four uprights or posts 3 which in turn carry a squeeze head designated generally by reference numeral 4 and which comprises individually operated squeezing members 5. The structure and operation of the jolting and squeezing means are fully described in said copending applications so will not be described in detail here. It is sufiicient to state that at the compacting station at which the jolting and squeezing means are disposed in the preferred embodiment of my invention shown in the drawings, which station is designated in the drawings by the letter C, the finely divided mold forming material which is disposed in the flasks against the patterns is compacted to form foundry molds.

At each end of the apparatus is what I term a stripping station designated by the letter S although as will presently appear functions other than a purely stripping function are performed at each of the stations S. Since the apparatus at both of the stations S is the same description of such apparatus at one such station will suflice.

Referring to the left-hand portion of Figure 3, the foundation carries fixed supporting elements 6 which in turn carry a fixed head 7 from which project upwardly four supporting and positioning posts 8. In the form shown in the drawings two of the posts 8 which are diagonally opposite each other are provided with upwardly projecting positioning members 9 so that a carrier carrying a pattern may be predeterminately supported and positioned on the posts 8.

The supporting framework has an upwardly projecting portion 10 which supports in stationary position at each side of the station S a series of rotatable rollers 11 constituting a roller table. One of the roller tables is for delivering away from the center line of the apparatus flasks with compacted molds therein and the other is for delivering empty flasks toward the center line of the apparatus. The direction of movement of the flasks to and from the stations S is from right to left viewing Figure 1. Flasks designated F are shown in chain lines in certain of the figures of the drawings.

At each of the stations S there is provided a vertical cylinder 12 in which operates a piston carrying a crosshead 13 having upwardly projecting arms 14 carrying freely rotatable rollers 15 at their upper extremities. The elements 13-1415 constitute a stripper and when a pattern carrier carrying a pattern and flask with a compacted mold therein is positioned upon the posts 8 and the piston in the cylinder 12 is moved upwardly the rollers 15 strip the flask and mold from the pattern and raise the flask to the elevation at which the flask F is shown in Figure 5 whereupon the flask may be delivered laterally upon one of the roller conveyors 11.

Connected with and extending downwardly from the crosshead 13 is a rod 16 which passes through a guide 17 in the fixed head 7 to prevent turning of the crosshead 13 relatively to the fixed head 7 and thus insure proper orientation of the rollers 15 at all times.

The supporting structure carries a transverse cylinder 18 in which operates a piston having piston rods 19 connected therewith and projecting from the cylinder 18 at both ends. Each of the piston rods 19 has adjacent its extremity a transverse member 20 with which are connected members 20a carrying rollers 21. The left-hand set of rollers 21 viewing Figure I ride in tracks 22 carried by the frame and the right-hand set of rollers 21 viewing Figure 1 ride in tracks 23 carried by the frame. Thus as the piston moves in the cylinder 18 the rollers 21 ride upon the tracks 22 and 23.

Pivoted to the members 20a are detents 24 adapted to engage the upper rim of a flask F as shown in Figure 4. Also connected with the members 20a is a plate 25 having at opposite faces bumpers 26 of rubber-like material. Projecting downwardly from the plate 25 is a compressed air pipe 27 connected with a transverse pipe 28 which is perforated at intervals along its length for the purpose of emitting jets of air to clean the pattern as will presently be described. Spraying means 29 are provided for spraying the pattern between uses for a purpose well known to those skilled in the art.

When a flask F with a compacted mold therein is disposed at either of the stripping stations S the flask and mold are stripped from the pattern by upward movement of the rollers 15 and the flask is raised to the elevation shown in Figure 5. An empty flask is delivered toward the left on the right-hand set of rollers 11 viewing Figure 4 until it engages the plate 25. While that flask is passing under the detents 24 the detents swing upwardly about their pivotal mountings to permit the flask to pass. When the flask reaches the position in which its lefthand edge is against the plate 25 the detents 24 drop down to the operative position shown in Figure 4. Thereupon the piston in the cylinder 18 is moved toward the left viewing Figure 4 and the plate 25 pushes out to the left the stripped flask with the compacted mold therein, such flask and mold being delivered upon the lefthand rollers 11. At the same time the right-hand flask is by the detents delivered from the right-hand rollers 11 onto the rollers 15 which are still in elevated position. When the right-hand flask F reaches its central position the piston in the cylinder 12 is lowered and the flask is seated upon the pattern P and centered by appropriate positioning pins as well known to those skilled in the art. Between the time when the flask containing the compacted mold is stripped and the new flask is set in place upon the pattern the pattern is cleaned and sprayed by the air jets from the perforated pipe 28 and the spray from the spray mechanism 29. The spray mechanism 29 is mounted in stationary position but the pipe 28 through which the jets of cleaning air are emitted moves with the plate 25 and hence traverses the pattern. The valves controlling the air and pattern spray may be timed so that at the conclusion of the cleaning of the pattern by the air jets the spray 29 is brought to bear upon the pattern. All this occurs while the pattern is free of any flask and the spray 29 is shut off before the new flask is seated on the pattern. The stroke of the piston in the cylinder 18 is determined by adjustable stop screws 30 engageable with the ends of the piston rods 19.

Adjacent each end of the apparatus are two opposed vertical cylinders 31 in which operate pistons whose piston rods 32 support for vertical movement an element designated generally by reference numeral 33. The element 33 carries a roller table consisting of a series of freely rotatable rollers 34 and also a cylinder 35 in which operates a piston having piston rods 36 projecting from both ends of the cylinder. Each piston rod 36 has adjacent its end an upward projection 37.

There is provided carrying means for the patterns, such carrying means comprising two separate carriers 38 and 39. There is a small space 40 (Figure 3) between the carriers 38 and 39. Each of the carriers 38 and 39 is adapted to have a pattern P bolted or otherwise fastened thereto and to provide for the application of fastening means each carrier has bores 41. During a production run of the apparatus a pattern P will be bolted to the carrier 38 and another pattern P will be bolted to the carrier 39. As above indicated those patterns may be identical or not; normally they Will be patterns for forming the cope and drag respectively of the same mold. The ends of the piston rods 36 carry freely rotatable inclined rollers 42 which ride on tracks 43 carried by the frame. The stroke of the piston in the cylinder 35 is determined by adjustable stop bolts 44.

When the element 33 is down, or in its lowermost position, the carriers 38 and 39 are supported only by the supporting means provided at the respective stations at which those carriers are positioned at the time. When, however, the element 33 is raised the projections 37 enter recesses 45 in the respective carriers 38 and 39 whereby the piston in the cylinder 35 is adapted to move both carriers synchronously longitudinally of the apparatus. When the element 33 reaches its uppermost position the carriers are supported upon the rollers 34 and are raised above the supporting means at the respective stations. This frees the carriers for longitudinal movement by the piston in the cylinder 35.

At each side of the compacting station C is a hopper or chute 46 adapted to receive finely divided mold forming material as from an endless conveyor 47 (Figure 5) and to deliver the finely divided mold forming material downwardly into a flask as the flask moves from one of the stripping stations S to the compacting station C. The amount of mold forming material delivered will be determined by the amount delivered upon the conveyor 47, and desirably the proper amount of mold forming material will be delivered to properly fill the flask. Thus the mold forming material is delivered into the initially empty flask as the flask is moving from one of the stripping stations S to the compacting station C. At the same time the mold forming material is struck off by a downwardly projecting vertically adjustable strick-off member 48 carried by the corresponding hopper or chute 46. Consequently as each flask moves to the compacting station it is filled with finely divided mold forming material and the mold forming material is struck oif.

A cycle of operation of the apparatus Will now be described. With reference initially to Figure 3, let it be considered that a pattern P with a flask F thereon carried by the carrier 39 has received finely divided mold forming material and the mold forming material has been compacted at the compacting station C by the combined jol-ting and squeezing of the means provided at that station as fully described in said copending applications. The jolt table has been stopped and the squeezing members 5 have been raised to inoperative position. At the same time a pattern P and an empty flask F are disposed on the carrier 38. The element 33 is down.

The element 33 is raised by admitting fluid under pressure beneath the pistons in the cylinders 31. The projections 37 enter the recesses 45 and the rollers 34 pick up the carriers 38 and 39 and raise them and the patterns and flasks carried thereby so as to free them from the supports at the respective stations. Thereupon fluid is admitted to the left of the piston in the cylinder 35 viewing Figure 3 and that piston is moved to the right carrying with it the carriers 38 and 39 and the patterns and flasks thereon. The movement is rapid until near the end of the stroke when it is cushioned by an air cylinder 49 which is duplicated at the opposite ends of the apparatus. The stroke is as above indicated determined by the adjustable stop bolt 44 at the right-hand end of Figure 3. The carrier 39 is stopped with the flask containing the 6 compacted mold centered at the right-hand stripping station S viewing Figure 3. During movement from the left-hand stripping station S to the compacting station C of the empty flask carried by the pattern on the carrier 38 that flask is filled with finely divided mold forming material delivered through the corresponding chute 46 and struck off by the strike-oif element 48. The carrier 38 stops in centered position at the compacting station C.

With the carrier 39 centered at the right-hand stripping station S viewing Figure 3 and the carrier 38 centered at the compacting station C the element 33 is lowered and the carrier 39 is supported and centered upon the posts 8 of the right-hand stripping station S viewing Figure 3. At the same time the carrier 38 with its pattern and flask filled with uncompacted mold forming material is centered at the compacting station upon the centering members 50. The mold forming material in the flask on the carrier 38 is compacted by the combined jolting and squeezing action at the compacting station. While such compacting is being eflected the flask at the right-hand stripping station S is stripped by upward movement of the rollers 15 which as above described raise the flask containing the compacted mold to the level of the rollers 11 whereupon the piston in the cylinder 18 is moved toward the left viewing Figure 4 delivering the flask with the compacted mold therein to the left and delivering an empty flask to centered position at the stripping station as above described. Thereupon the rollers 15 are moved downwardly and the empty flask is seated upon the pattern carried by the carrier 39.

It should be explained that it is not essential that the carrier 39 and pattern P with the flask F thereon be seated upon the posts 8 of the right-hand stripping station S viewing Figure 3 when the element 33 is lowered as described in the first sentence of the next preceding paragraph, as the rollers 15 of the right-hand stripping station S viewing Figure 3 may start their upward movement and strip the flask from the pattern before the carrier 39 and pattern reach supported position on the 7 posts 8; or the upward movement of the rollers 15 .may be started while the element 33 carrying the carrier 39 and the pattern and flask thereon with a compacted mold in the flask is lowering but timed to strip the flask from the pattern just as or immediately after the carrier 39 seats on the posts 8.

The foregoing description covers a half cycle of operation of the apparatus. The succeeding half cycle is started by raising the element 33 as described at the beginning of the third preceding paragraph, but the succeeding movement of the carriers 38 and 39 is to the left viewing Figure 3 instead of to the right. The steps thereafter are analogous and parallel to those above described but to the left viewing Figure 3 instead of to the right.

Thus I form and deliver with great accuracy and with unprecedented efliciency compacted molds of mold forming material adapted for casting in the foundry. If the molds produced by use of my apparatus are cope and drag molds adapted to be assembled to form a complete mold for casting, means may be provided for inverting the cope molds and bringing them into position over the drag molds as they are being delivered toward the casting station.

While I have illustrated and described a present preferred method of practicing the invention it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously practiced within the scope of the following claims.

I claim:

1. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides to a compacting station, during such shifting of each such pattern and flask introducing finely divided mold forming material into the flask and against the pattern, at the compacting station compacting the finely divided mold forming material in each flask against the pattern carrying the flask, shifting each pattern and flask with a compacted mold thereon and therein away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station, stripping each flask and mold from the pattern against which the mold was formed, conveying away the flask and mold in a direction transverse of the direction of movement of the pattern, flask and mold away from the compacting station and simultaneously with such conveying away of the flask and mold moving another flask in the same transverse direction into position opposed to the pattern whence the flask and pattern are relatively moved into cooperative relationship for reception of finely divided mold forming material to form another mold.

2. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides to a compacting station, during such shifting of each such pattern and flask introducing finely divided mold forming material into the flask and against the pattern, at the compacting station compacting the finely divided mold forming material in each flask against the pattern carrying the flask, shifting each pattern and flask with a compacted mold thereon and therein away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station, stripping each flask and mold from the pattern against which the mold was formed, conveying away the flask and mold in a direction transverse of the direction of movement of the pattern, flask and mold away from the compacting station and simultaneously with such conveying away of the flask and mold moving another flask in the same transverse direction into position opposed to the pattern whence the flask and pattern are relatively moved into cooperative relationship for reception of finely divided mold forming material to form another mold and, between the stripping of the flask and mold from the pattern against which the mold was formed and the relative movement of the pattern and the other flask into cooperative relationship for reception of finely divided mold forming material to form another mold, cleaning and spraying the pattern.

3. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides generally horizontally to a compacting station, introducing finely divided mold forming material into each flask and against the pattern therein, at the compacting station, lowering such pattern and flask with mold forming material therein into operative position, compacting the mold forming material in such flask against the pattern therein, thereafter raising such pattern, flask and mold and then shifting such pattern, flask and mold generally horizontally away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station and stripping such flask and mold from such pattern.

4. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides generally horizontally to a compacting station, introducing finely divided mold forming material into each flask and against the pattern therein, at the compacting station lowering such pattern and flask with mold forming material therein into operative position, compacting the mold forming material in such flask against the pattern therein, thereafter raising such pattern, flask and mold and then shifting such pattern, flask and mold generally horizontally away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station and raising such flask and mold to strip such flask and mold from such pattern.

5. A method of forming foundry molds comprising shifting patterns each witha flask thereon alternately from opposite sides generally horizontally to a compacting station, introducing finely divided mold forming material into each flask and against the pattern therein, at the compacting station compacting the finely divided mold forming material into each flask and against the pattern therein, shifting such pattern, flask and mold away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station, raising such flask and mold to strip such flask and mold from such pattern and conveying away such flask and mold generally horizontally at the elevation to which such flask and mold are raised to strip them from such pattern.

6. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides generally horizontally to a compacting station, introducing finely divided mold forming material into each flask and against the pattern therein, at the compacting station compacting the finely divided mold forming material into each flask and against the pattern therein, shifting such pattern, flask and mold away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station, raising such flask and mold to strip such flask and mold from such pattern, conveying away such flask and mold generally horizontally at the elevation to which such flask and mold are raised to strip them from such pattern and moving another flask into position above such pattern and lowering such other flask into cooperative relationship with such pattern for reception of finely divided mold forming material to form another mold.

7. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides generally horizontally to a compacting station, introducing finely divided mold forming material into each flask and against the pattern therein, at the compacting station compacting the finely divided mold forming material into each flask and against the pattern therein, shifting such pattern, flask and mold away from the compacting station in the direction opposite'the direction of shifting of the same pattern and flask to the compacting station, raising such flask and mold to strip such flask and mold from such pattern, conveying away such flask and mold generally horizontally and simultaneously moving another flask following up such flask and mold being conveyed away into position above such pattern and lowering such other flask into cooperative relationship with such pattern for reception of finely divided mold forming material to form another mold.

8. A method of forming foundry molds comprising shifting patterns each with a flask thereon alternately from opposite sides generally horizontally to a compacting station, introducing finely divided mold forming material into each flask and against the pattern therein, at the compacting station compacting the finely divided mold forming material into each flask and against the pattern therein, shifting such pattern, flask and mold away from the compacting station in the direction opposite the direction of shifting of the same pattern and flask to the compacting station, raising such flask and mold to strip such flask and mold from such pattern, conveying away such flask and mold generally horizontally, moving another flask into position above such pattern and lowering such other flask into cooperative relationship with such pattern for reception of finely divided mold forming material to form another mold and, between the raising of such flask and mold to strip such flask and mold from such pattern and the lowering of the other flask into cooperative relationship with such pattern, cleaning and spraying such pattern.

(References on following page) References Cited in the file of this patent UNITED STATES PATENTS 10 Gedris June 8, 1954 Miller Oct. 20, 1959 FOREIGN PATENTS France June 23, 1954 Canada Apr. 10, 1956 

